Fatigue management system

A method for relating a stream of flight data of an aircraft to loads experienced at a plurality of locations of the aircraft, the method comprising the steps of:

• storing load data detected by on board real load sensors during at least one precedent load classification flight at predetermined locations of an aircraft and associated to respective causative operational conditions due to pilot input parameters collected during said classification flights;
• receiving at least one input for a pilot's parameters to operate the aircraft subsequent to said classification flights;
• correlating the pilot's parameters to directly link, without use of real load sensors, the pilot's input to an on board virtual load sensor to associate the pilot's parameters and related flight parameters via the respective causative operational conditions collected during said classification flights to the corresponding load data from the at least one precedent load classification flight;
• training a heuristic algorithm using classification flight data and the flight parameters from the load data detected with the real sensors;
• pre-processing the flight parameters using moving average and calculating mean and gradient values within a sequence, which is a definite period of time/number of samples;
• grouping minimum, maximum and oscillation frequency values of the loads in categories of nominal values instead of continuous values;
• associating pre-processed flight parameters with dedicated load classes and oscillation frequency of said categories using said heuristic algorithm;
• reconverting associated nominal load classes to continuous minimum and maximum load values per sequence;
• giving output loads in minimum, maximum and oscillation frequency values allowing to reconstruct a complete load history;
• processing minimum and maximum values of the loads to determine arithmetic mean and amplitude load values;
• using minimum/maximum and oscillating frequency values represented in the load categories to reconstruct the load history;
• processing arithmetic mean, amplitude and frequency values of calculated loads to determine a rainflow matrix for each dedicated location by range-pair-range algorithm;
• calculating cumulated fatigue using the rainflow-matrix to determine the actual component usage during flight;
• and
• calculating any damage per dedicated component / location during flight.

A fatigue management system for determining the individual life of components of an aircraft by a virtual load sensor on board the aircraft, the virtual load sensor comprising;

• a data storage with load data detected by real load sensors on board a classification aircraft at predetermined locations of the classification aircraft during at least one precedent load classification flight of the classification aircraft and associated to respective causative operational conditions due to pilot input parameters collected during the classification flights;
• control means for at least one pilot input to operate the aircraft;
• and
• correlation means to directly link, without the use of real load sensors, the at least one pilot input to the virtual load sensor to associate the pilot input parameters and related flight parameters via the respective causative operational conditions collected during the classification flights to the corresponding load data from the at least one precedent load classification flight.